Caterpillar 120H & 135H Motor Graders Grader Factory Service & Shop Manual
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Complete workshop repair & service manual with electrical wiring diagrams for Caterpillar 120H & 135H Motor Graders. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.
This Caterpillar 120H & 135H Motor Graders service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.
MANUAL LIST:
RENR1416 - Specifications (120H & 135H Motor Graders Air System & Brakes)
RENR1431 - Schematic (120H Motor Grader ES Version Hydraulic Systems)
RENR1439 - Schematic (120H Motor Grader (ES Version) Electrical System)
SENR6984 - Schematic (120H (ES Version) Motor Grader Electrical System)
SENR6994 - Specifications (120H & 135H Motor Graders Power Train)
SENR8523 - Specifications (120H & 135H Motor Graders Air System & Brakes)
SENR8538 - Disassembly & Assembly (Supplement for 120H & 135H Motor Graders - 3116 Engine)
SENR8543 - Disassembly & Assembly (120H & 135H Motor Graders Power Train)
SENR8544 - Disassembly & Assembly (120H & 135H Motor Graders Machine System)
SENR8557 - Specifications (120H Motor Grader Hydraulic & Steering System)
SENR8592 - Schematic (120H ES Version Motor Grader Hydraulic Systems)
SENR9059 - Specifications (120H, 12H, 135H, 140H, 143H, 14H, 160H, 163H & 16H Motor Graders Secondary Steering System)
SENR9059 - Systems Operation (120H, 12H, 135H, 140H, 143H, 14H, 160H, 163H & 16H Motor Graders Secondary Steering System)
SENR9059 - Testing & Adjusting (120H, 12H, 135H, 140H, 143H, 14H, 160H, 163H & 16H Motor Graders Secondary Steering System)
SENR9102 - Schematic (120H ES Version Motor Grader Hydraulic Systems)
SENR9157 - Specifications (120H & 135H Motor Graders Power Train)
SENR9179 - Specifications (120H & 135H Motor Graders Hydraulic & Steering System)
RENR1426 - Schematic (120H & 135H Motor Grader Standard Version Electrical System).pdf
RENR1440 - Schematic (120H & 135H Motor Grader Standard Version Electrical System).pdf
SENR8570 - 120H & 135H Standard Versions Motor Graders Hydraulic System.pdf
...
EXCERPT:
1. Remove plug (1) and drain the oil from the circle drive housing in a suitable container for storage or disposal. The capacity of the circle drive housing is 7 L (1.8 gal U.S.). Install plug (1).
2. Bend lock (2) away from nut (3).
3. Remove nut (3), lock (2), spacer (4) and the O-ring seal from circle drive shaft (7).
4. Remove nuts (6) and washers from the long studs of the circle drive housing.
5. Install Tooling (A) and a hoist to the circle drive housing.
6. Remove bolts (8) and the spacers that hold the circle drive housing to the circle draw bar.
7. Lift the circle drive enough in order to remove pinion gear (5) from shaft (7) and from engagement with the circle. Remove the circle drive from the circle. The weight of the circle drive is 45 Kg (100 lb).
8. Remove the Duo-Cone seal from the pinion.
Install Circle Drive
...
RENR1416 - Specifications (120H & 135H Motor Graders Air System & Brakes)...1
Air Compressor...2
Air Compressor Governor...4
Air Tank...5
Relief Valve (Air Tank)...6
Solenoid Valve (Air Horn)...7
Air Horn...9
Air Dryer...11
Pressure Switch (Low Brake Air)...13
Pressure Switch (Brake Air) (Stop Lamp)...14
Front Wiring...15
Service Brake Control...17
Air Control Valve (Parking Brake)...20
Check Valve (Parking Brake Release)...21
Solenoid Valve (Parking Brake)...22
Pressure Switch (Brake Air) (Parking Brake)...23
Service Brakes...24
Parking Brake...27
RENR1426 - Schematic (120H & 135H Motor Grader Standard Version Electrical System)...29
Features...29
Cover Page...30
Information...0
Component Location...31
Connector Location...32
CID/MID/FMI...33
Specifications And Related Manuals...34
Wire Description...35
Electrical Symbols...36
Schematic...37
Machine View...0
Machine Harness Connector And Component Locations...38
RENR1431 - Schematic (120H Motor Grader ES Version Hydraulic Systems)...39
Main...40
RENR1439 - Schematic (120H Motor Grader (ES Version) Electrical System)...42
Main...43
Collage...45
RENR1440 - Schematic (120H & 135H Motor Grader Standard Version Electrical System)...55
Features...55
Cover Page...56
Information...0
Component Location...57
Connector Location...58
CID/MID/FMI...59
Specifications And Related Manuals...60
Electrical Symbols...61
Schematic...62
Machine View...0
Machine Harness Connector And Component Locations...63
SENR6984 - Schematic (120H (ES Version) Motor Grader Electrical System)...64
Main...65
Collage...67
SENR6994 - Specifications (120H & 135H Motor Graders Power Train)...94
Magnetic Screen (Transmission)...95
Gear Pump (Transmission Charging and Scavenge)...97
Transmission Oil Lines...99
Oil Filter (Power Train)...100
Governor Control...103
Clutch Control (Modulation)...106
Transmission Case...113
Transmission...115
Transmission Control Valve...128
Selector and Pressure Control Valve...133
Pressure Switch (Transmission Modulation)...146
Solenoid Valve (Transmission Clutch)...149
Speed Sensor (Transmission Output)...152
Temperature Sensor (Transmission Oil)...153
Drive Shaft...154
Differential and Bevel Gear...155
Differential...162
Solenoid Valve (Differential Lock)...164
Final Drive...168
Tandem and Cover...170
Drive Chain...172
Wheel Group...174
Solenoid Valve (Centershift Lock)...176
Case and Frame...177
Rollover Protective Structure (ROPS) - If Equipped SMCS - 7325...179
Window Wipers...181
Window Washer...183
Air Conditioner...184
SENR8523 - Specifications (120H & 135H Motor Graders Air System & Brakes)...186
Air Compressor Governor...187
Air Tank...189
Relief Valve (Air Tank)...190
Solenoid Valve (Air Horn)...191
Air Horn...193
Air Dryer...195
Pressure Switch (Low Brake Air)...197
Pressure Switch (Brake Air) (Stop Lamp)...198
Front Wiring...200
Service Brake Control...202
Air Control Valve (Parking Brake)...205
Check Valve (Parking Brake Release)...206
Solenoid Valve (Parking Brake)...207
Pressure Switch (Brake Air) (Parking Brake)...209
Service Brakes...210
Parking Brake...213
SENR8538 - Disassembly & Assembly (Supplement for 120H & 135H Motor Graders - 3116 Engine)...215
Batteries...216
Batteries & Battery Boxes...218
Exhaust Pipe Assembly...221
Prescreener Assembly...222
Hood...223
Air Cleaner Group...225
Muffler...228
Turbocharger...229
Alternator...231
Fan Spider Assembly...233
Fan Drive...235
V-Belts...239
Electric Starting Motor...240
Air Compressor...241
Air Conditioning Compressor...244
Engine Oil Filler Group...246
Engine Oil Filter & Oil Filter Base...247
Engine Oil Cooler...251
Transmission Oil Cooler...254
Fuel Priming Pump...256
Fuel Filter & Fuel Filter Base...257
Water Separator Group...259
Radiator...261
Water Temperature Regulator...266
Water Pump...268
Water Pump Drive...274
Pump Group Drive Shaft...277
Speedometer & Tachometer Sensor...279
Engine...280
SENR8543 - Disassembly & Assembly (120H & 135H Motor Graders Power Train)...292
Conventional Duo-Cone Seals...293
Rear Tires & Rims...300
Drive Chains...302
Brake & Wheel Spindle Housings...306
Differential Drive Shaft...315
Parking Brake...317
Tandem Drive Housings...326
Drive Sprockets...328
Final Drives...331
Transmission Speed Sensor...342
Transmission Oil Filter...344
Transmission Oil Filter Base...346
Transmission Magnetic Screen Filter Group...348
Transmission Magnetic Screen Filter Base...350
Transmission Oil Pump...352
Transmission Oil Cooler...359
Transmission Hydraulic Control Valve...362
Transmission...386
Differential & Bevel Gear...433
Differential Lock Control Valve...452
Transmission & Transmission Hydraulic Control Valve; Testing and Adjusting...454
SENR8544 - Disassembly & Assembly (120H & 135H Motor Graders Machine System)...467
Conventional Duo-Cone Seals...469
Front Tires & Rims...476
Front Wheel Spindles...478
Front Wheel Spindle Housings...483
Steering Metering Pump...489
Steering Cylinders...504
Steering Tie Rod...511
Steering Hydraulic Accumulator...513
Wheel Lean Arms...516
Wheel Lean Bar...523
Wheel Lean Cylinder...526
Front Axle Group...532
Blade Lift Accumulators...538
Blade Lift Cylinders...541
Ball & Socket Joint Inserts...547
Blade Lift Arms...549
Centershift Lock...557
Blade Lift Bar_Centershift Lock Bar...562
Centershift Lock Control Valve...565
Centershift Lock Bar Bushings...569
Blade Side Shift Cylinder...572
Blade Centershift Cylinder...581
Blade Tip Cylinder...587
Swivel Group...594
Blade...600
Blade Assembly...604
Circle...610
Circle Draw Bar...614
Circle Drive Motor...622
Circle Drive...630
Seat Assembly...643
Cab...645
Hydraulic Oil Tank Filter...654
Hydraulic Oil Tank...656
Implement Pump Drive...660
Implement Hydraulic Pump...662
Implement Control Valves...678
Combination Valve...691
Compensator Valve...700
Air Dryer Group...708
Parking Brake Control Air Valve Assembly...710
Parking Brake Solenoid Valve...715
Brake Control Air Valve...716
Differential Lock Actuator Valve...723
Fuel Tank...726
Articulation Cylinders...731
Supplemental Steering...739
Main Frames...742
Pivot Pin Bearings...756
Rear Bumper...761
Ripper Lift Cylinder...764
Ripper...771
Air Tank...787
Scarifier Lift Cylinder...790
Scarifier...796
SENR8557 - Specifications (120H Motor Grader Hydraulic & Steering System)...805
Piston Pump (Hydraulic and Steering)...807
Pump Control Valve (Pressure and Flow Compensator)...813
Steering Control...815
Pump Drive Shaft...816
Metering Pump (Steering)...817
Hydraulic Tank Mounting...820
Hydraulic Tank and Filter...821
Operator Console...823
Valve and Linkage Group...826
Steering Accumulator...828
Control Valve (Blade Tip)...829
Control Valve (Blade Lift)...832
Circle Drive Control Valve...834
Articulation Control Valve...836
Control Valve (Scarifier)...838
Control Valve (Wheel Lean)...841
Ripper Control Valve...843
Centershift Control Valve...846
Sideshift Control Valve...849
Scarifier Relief Valve...851
Blade Tip Relief Valve...853
Sideshift Relief Valve...855
Blade Lift Relief Valve...857
Ripper Relief Valve...859
Relief Valve (Implement)...861
Combination Valve...862
Solenoid Valve (Centershift Lock)...866
Relief Valve (Steering)...867
Relief Valve (Signal)...869
Articulation Cylinder...870
Blade Lift Cylinder...872
Blade Tip Cylinder...874
Centershift Cylinder...876
Ripper Lift Cylinder...878
Ripper Cylinder and Lines...880
Scarifier Cylinder...881
Sideshift Cylinder...883
Steering Cylinder...885
Wheel Lean Cylinder...887
Articulation Cylinder Mounting...889
Blade Lift Cylinder Mounting...891
Wheel Lean Cylinder and Mounting...892
Centershift Cylinder Mounting...893
Articulated Hitch...894
Scarifier...896
Swivel...899
Circle Drive...900
Circle Drive - Slip Clutch...902
Blade Lift...907
Circle...909
Drawbar...911
Front Axle...915
SENR8570 - 120H & 135H Standard Versions Motor Graders Hydraulic System...921
SENR9102 - Schematic (120H ES Version Motor Grader Hydraulic Systems)...923
Main...924
SENR9157 - Specifications (120H & 135H Motor Graders Power Train)...926
Magnetic Screen (Transmission)...927
Gear Pump (Transmission Charging and Scavenge)...929
Transmission Oil Lines...931
Oil Filter (Power Train)...933
Governor Control...936
Clutch Control (Modulation)...939
Transmission Case...946
Transmission...948
Transmission Control Valve...961
Selector and Pressure Control Valve...966
Pressure Switch (Transmission Modulation)...980
Solenoid Valve (Transmission Clutch)...984
Speed Sensor (Transmission Output)...987
Drive Shaft...989
Differential and Bevel Gear...990
Differential...997
Solenoid Valve (Differential Lock)...999
Final Drive...1003
Tandem and Cover...1005
Drive Chain...1007
Wheel Group...1009
Solenoid Valve (Centershift Lock)...1011
Case and Frame...1012
Rollover Protective Structure (ROPS) - If Equipped SMCS - 7325...1014
Window Wipers...1016
Window Washer...1018
Air Conditioner...1019
SENR9179 - Specifications (120H & 135H Motor Graders Hydraulic & Steering System)...1021
Hydraulic Tank and Filter...1023
Hydraulic Tank Mounting...1025
Piston Pump (Hydraulic and Steering)...1026
Pump Control Valve (Pressure and Flow Compensator)...1032
Pump Drive Shaft...1034
Steering Control...1035
Metering Pump (Steering)...1036
Accumulator (Steering)...1039
Accumulator (Blade Cushion)...1040
Solenoid Valve (Blade Cushion)...1042
Valve and Linkage Group...1044
Articulation Control Valve...1048
Control Valve (Blade Lift)...1050
Blade Lift Control Valve...1053
Control Valve (Blade Tip)...1056
Circle Drive Control Valve...1059
Ripper Control Valve...1061
Control Valve (Scarifier)...1064
Sideshift Control Valve...1067
Control Valve (Snow Plow_Dozer Lift)...1069
Control Valve (Wheel Lean)...1072
Relief Valve (Blade Lift)...1074
Relief Valve (Blade Tip)...1076
Relief Valve (Implement)...1078
Relief Valve (Ripper)...1079
Relief Valve (Scarifier)...1083
Relief Valve (Sideshift)...1085
Relief Valve (Signal)...1087
Relief Valve (Snow Plow_Dozer Lift)...1088
Relief Valve (Steering)...1090
Articulation Cylinder...1092
Blade Lift Cylinder...1096
Blade Tip Cylinder...1098
Centershift Cylinder...1100
Ripper Lift Cylinder...1102
Ripper Cylinder and Lines...1104
Scarifier Cylinder...1106
Sideshift Cylinder...1108
Steering Cylinder...1110
Wheel Lean Cylinder...1114
Articulation Cylinder Mounting...1116
Blade Lift Cylinder Mounting...1118
Centershift Cylinder Mounting...1119
Wheel Lean Cylinder and Mounting...1120
Centershift Lock...1121
Solenoid Valve (Centershift Lock)...1123
Operator Console...1124
Articulated Hitch...1127
Articulation Position Sender...1129
Blade Lift...1130
Gerotor Motor (Circle Drive)...1132
Circle...1133
Circle Drive...1135
Drawbar...1142
Front Axle...1146
Scarifier...1152
Swivel...1155